Golf club head and a method for manufacturing the same

ABSTRACT

A golf club head has a metal base, face and tubular neck and a carbon-fiber cover. The face extends up vertically from one edge of the base. The tubular neck is integrally connected to the base and the face. The cover is made of a carbon-fiber material and is securely attached to the base and the face. Because the carbon-fiber material is lighter than metal, the area of the face is enlarged. In addition, the shock absorbing effect of the golf head club is also improved.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to a golf club head and the methodfor forming the same, and more particularly to a golf club head with alarge hitting face and good flexibility.

[0003] 2. Description of Related Art

[0004] In general, one of two ways are usually used to manufacture agolf club head. One is to form the head with a cast mold process, andthe other is to weld several parts together. However, because theconventional golf club head is always made of metal and the weight ofthe golf club head is standardized, the area of the face of the golfclub head is limited. A new golfer easily misses the golf ball with agolf club having a conventional head. In addition, the shock absorbingeffect of the conventional golf club head formed by combining severalparts is easily reduced because of the welding process.

[0005] To overcome the shortcomings, the present invention tends toprovide an improved golf club head to mitigate or obviate theaforementioned problems.

SUMMARY OF THE INVENTION

[0006] The main objective of the invention is to provide an improvedgolf club head having a face with a large area. The golf club head has ametal base, face and tubular neck and a carbon fiber cover. The faceextends up vertically from one edge of the base. The tubular neck isintegrally connected to the base and the face. The cover is securelyattached to the base and the face. Because the carbon-fiber material islighter than the metal, the area of the face is enlarged. In addition, abetter shock absorbing effect is achieved due to the carbon-fiber cover.

[0007] Other objects, advantages and novel features of the inventionwill become more apparent from the following detailed description whentaken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008]FIG. 1 is an exploded perspective view of a golf club head inaccordance with the present invention;

[0009]FIG. 2 is a block diagram of a method for manufacturing the golfclub head in FIG. 1;

[0010]FIG. 3 is a side plan view in partial section of the golf clubhead in FIG. 1 with an air bag; and

[0011]FIG. 4 is a side plan view in partial section of the golf clubhead in FIG. 1.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

[0012] With reference to FIG. 1, a golf club head in accordance with thepresent invention comprises a base (10), a face (11), a neck (12) and acover (20). The base (10) is made of metal. A countersunk threaded hole(15) is defined in the base (10). A countersunk recess (16) is definedin the base (10) around the threaded hole (15). A threaded plug (18)with an enlarged head (17) is screwed into the threaded hole (15).Consequently, the threaded plug (18) is securely attached to the base(10) due to the engagement with the threaded hole (15).

[0013] The face (11) extends up vertically from one edge of the base(10). Grooves are defined on the outside of the face (11). The neck (12)is a tubular member and is integrally connected to the base (10) and theface (11). A lip (14) is formed around the edges of the base (10) toform a cavity (13) between the base (10), the lip (14) and the face(11).

[0014] The cover (20) is securely attached to the lip (14) and the face(11) to cover the cavity (13). At least one weighted plug (22) with anannular recess (23) in the outer edge is inlaid in the cover (20). Abore (21) is formed in the cover (20) to securely hold each weightedplug (22).

[0015] With reference to FIG. 1 and 2, the process of manufacturing thegolf club head comprises the following steps:

[0016] a. forming the base (10) and the face (11):

[0017] The base (10) with the lip (14) and the face (11) are castmolded. Then, the tubular neck (12) is formed with a forging process.The countersunk threaded hole (15) and the circular recess (16) aredrilled in the base (10) and the threaded hole (15) tapped.

[0018] b. thermal treatment:

[0019] The body comprising the base (10), the lip (14), the face (11)and the neck (12) is thermally treated.

[0020] c. grinding:

[0021] The body is then ground to a desired shape and size.

[0022] d. spraying aluminum oxide sand onto the body:

[0023] By spraying the aluminum oxide sand onto the inner surface of thecavity (13) of the body and the edge around the cavity (13), the surfaceroughness of the body is increased.

[0024] e. attaching the cover (20) to the body:

[0025] The cover (20) formed with multiple carbon-fiber layers. Multiplebores (21) are defined in the cover (20). The cover (20) with bores (21) is attached to the body to cover the cavity (13).

[0026] f. inlaying the weighted plugs (22) into the cover (20):

[0027] A weighted plug (22) is put into each bore (21) in the cover(20).

[0028] g. inserting an air bag (30) into the body:

[0029] With reference to FIGS. 2 and 3, an air bag (30) is inserted intothe cavity (14) through the threaded hole (15) in the base (10). Thebody with the air bag (30) is then put into a hot-pressing machine.

[0030] h. inflating the air bag (30) and hot pressing:

[0031] The air bag (30) is inflated and expands to abut the innersurface of the cover (20) and the body, such that the outer surface ofthe cover (20) will press against the entire inner face of the mold inthe hot-pressing machine. During the hot-pressing mold process, thecover (20) will harden and form to a shape conforming to the shape ofthe hot-pressing mold. The cover (20) will be securely attached to thebase (10) and the face (11). Because the edge of the base (10) and theface (11) was sprayed with the aluminum oxide sand, the attachmentbetween the cover (20) and the body is enhanced. The weighted plugs (22)received in the bores (21) will be securely held into the cover (20)when the cover (20) hardens during the hot-pressing mold process. Inaddition, with reference to FIG. 4, a rib (212) will be automaticallyformed in each bore (21) during the hot-pressing mold process to engagethe annular recess (23) in each weighted plug (22). The combinationbetween each weighted plug (22) and the cover (20) is enhanced. Inanother embodiment, an annular rib is formed on an outer edge of eachweighted plug (22), such that a recess engaging with the rib of eachsecond block (22) will be defined in each bore (21) during thehot-pressing mold process.

[0032] i. attaching the threaded plug (18) to the base (10):

[0033] The air bag (30) is taken out of the body. The threaded plug (18)is screwed into the threaded hole (15) in the base (10) so that the head(17) is flush with the outer surface of the base (10). Consequently, theposition of the center of gravity of the golf club head is adjustablebased on the size and placement of the threaded plug (18) and weightedplugs (22).

[0034] j. fine grinding:

[0035] To increase the smooth of the surface of the golf club head, afine grinding process is carried out.

[0036] k. coating: and

[0037] The outer surface of the golf club head is coated with lacquer toprovide a protective coating on the head.

[0038] l. packing:

[0039] The golf club head is packed.

[0040] Accordingly, a golf club head with a carbon-fiber cover (20) ismade. Because the weight of the carbon-fiber material is lighter thanthe metal, the weight of the golf club head is reduced. Consequently, aface (11) with a larger area can be formed on the golf club head that isthe same weight as the conventional golf club head made of metal. Theface is enlarged. The likelihood of completely missing the golf ball canbe greatly reduced. In addition, because the elasticity of thecarbon-fiber material is better than that of the metal material, theshock absorbing effect of the golf club head is improved.

[0041] Even though numerous characteristics and advantages of thepresent invention have been set forth in the foregoing description,together with details of the structure and function of the invention,the disclosure is illustrative only, and changes may be made in detail,especially in matters of shape, size, and arrangement of parts withinthe principles of the invention to the full extent indicated by thebroad general meaning of the terms in which the appended claims areexpressed.

What is claimed is:
 1. A golf club head comprising: a metal base; ametal face extending up vertically from one edge of the base; a tubularneck integrally connected to the base and the face; and a cover made ofa carbon-fiber material and securely attached to the base and the face.2. The golf club head as claimed in claim 1 , wherein a lip extendsvertically from an edge of the base to connect to the cover.
 3. The golfclub head as claimed in claim 1 , wherein a countersunk threaded hole isdefined in the base.
 4. The golf club head as claimed in claim 1 ,wherein a threaded plug with an enlarged head and a threaded shaft isscrewed into the countersunk threaded hole in the base.
 5. The golf clubhead as claimed in claim 1 , wherein at least one bore is formed in aside of the cover.
 6. The golf club head as claimed in claim 5 , whereina weighted plug is inlaid in each bore in the cover.
 7. The golf clubhead as claimed in claim 6 , wherein an annular recess is defined in anouter edge of each weighted plug.
 8. The golf club head as claimed inclaim 6 , wherein an annular rib is formed on an outer edge of eachweighted plug.
 9. A method for manufacturing a golf club head, themethod comprising the following steps: a. integrally forming the bodycomprising a base and a face of metal in a casting molding process andforming a tubular neck of metal on the body by a forging process suchthat a cavity is defined between the base and the face; b. sprayingaluminum oxide sand onto an inner surface of the cavity and an outeredge around the cavity to increase a surface roughness of the body; c.attaching a cover formed from multiple carbon-fiber layers to the bodyto cover the cavity; and d. attaching the cover to the body in ahot-pressing mold process such that a golf club head with a carbon-fibercover is made.
 10. The method for manufacturing a golf club head asclaimed in claim 9 further comprising a step of a thermal treatment tothe body after the body is formed
 11. The method for manufacturing agolf club head as claimed in claim 10 further comprising a step ofgrinding the body after the thermal treatment process to form the bodyto a desired shape and size.
 12. The method for manufacturing a golfclub head as claimed in claim 9 , wherein at least one bore is definedin the cover to receive a weighted plug.
 13. The method formanufacturing a golf club head as claimed in claim 9 , wherein acountersunk through hole is defined in the base after the body isformed; the through hole is tapped; and a plug with a threaded shaft isscrewed into the threaded hole.
 14. The method for manufacturing a golfclub head as claimed in claim 13 , wherein an air bag is inserted intothe body with the cover through the threaded hole before thehot-pressing mold process is processed; the air bag is inflated andexpands to press against the inner surface of the cover and the bodyduring the hot-pressing mold process to form the cover into a desiredshape; the air bag is taken out of the body after the cover hashardened; and the threaded plug is screwed into the threaded hole in thebase.
 15. The method for manufacturing a golf club head as claimed inclaim 9 further comprising a step of fine grinding to increase thesmooth of a surface of the golf club head.
 16. The method formanufacturing a golf club head as claimed in claim 15 further comprisinga step of applying a lacquer coating to an outer surface of the goldclub head to provide a protective coating on the golf club head.
 17. Themethod for manufacturing a golf club head as claimed in claim 9 ,wherein a lip is formed on an edge of the body to connect to the cover.